Composition stick for filling small regular cavities



'June 1, 1965 J. F. LEUTZINGER 3,186,356

COMPOSITION STICK FOR FILLING SMALL REGULAR CAVITIES Filed Nov. 15. 1954 JOHN F. LEUTZINGER INVENTOR.

BY M 7 United States Patent 3,186,$56 COMPQSI'HGN TECK FOR FILLENG SMALL REGULAR CAVITES Iiohn F. Leutzinger, 132i? Republican, Seattle, Was Filed Nov. 15, 1954, Ser. No. 468,734 9 Claims. ((31. 1%245) This application concerns a wax based stick used for filling nail holes and like cavities in p-refinished materials, such as hardwood faced panels, and maintaining the prefinished appearance in the fill d area. When such stick is formed and applied in the manner disclosed herein, most satisfactory results will be obtained.

The finishing of wood panels and associated moldings in the past has been approached in a haphazard manner. In late years, however, many wood panels intended for paneling are p-reiinished by the manufacturer so that the consumer no longer need rely on the skill of his carpenter or painter and the operating conditions on the job. Panels of this type are often thin and of considerable width and to preserve the fiat reflective surface without distortion and to adequately secure the same, the most feasible arrangement for securing the panels to a wall is by face nailing.

Face nailing of course leaves the nail holes to be filled. In the past, these holes often were filled by putty mixed on the job with coloring agents to simulate the color of the finish f the material. The results have been rather unsatisfactory because of (l) shrinkage of the putty after installation, (2) dullness of the putty compared with the surrounding glossy surface, (3) scratching of the surrounding surface in applying the putty with a putty knife, or the like, and (4) failure to match the panel coloring by ad hoc color mixing.

The objects of my invention include, therefore, the following: to devise a material for filling nail holes in prefinished wood materials, as well as other cavities in prefinished materials, so as to preserve the appearance of the panel in the area of the filling; to provide in such filler a gloss comparable to the panel finish; to provide non-shrinking characteristics so that the filling, when filled flush with the panel, will remain fiush; to provide a filler and a method of applying the material so that there will be no marring of the surrounding area; to provide a filler of economical material and manufacture meeting all of the above requirements; and to provide a simple method of and material for application to meet conditions ranging from those occurring in a manufacturing plant to those occurring in the small job conducted by the consumer himself.

Further objects include providing such filler formable in an economical commercial operation into an elongated body having workable characteristics at normal building temperatures but preserved in storage under unusual temperatures.

My invention, together with additional objectives and advantages thereof, will be best understood from a reading of the following specification, with reference to the drawings, in which:

FIGURE 1 is a cross sectional view showing the mannor in which the filler is applied to the work to fill a nail hole, secondary position of the hand being shown in dashed lines;

FEGURE 2 is a cross sectional view showing the final wiping operation which completes the treatment of a single nail hole; and

FIGURE 3 is a perspective view, partly in section, showing the finished, filled nail hole.

THE METHOD OF APPLICATION Referring more particularly to the disclosure of the drawings, the numeral 14 designates a typical large wall panel. Such panels may be of various sizes and the larger sizes extend from the floor to the ceiling and are four feet in width. Such panels are normally made of several wood plies covered with an outer layer of choice wood.

Such a panel is normally made under carefully controlled conditions wherein the moisture content is controlled so that tlie finished board will be true and will not warp. The ideal time to finally finish this panel is before it has had a chance to undergo the change which will usually occur in storage. Persons skilled in finishing work can fill or seal such woods or stain or bleach them to the color desired and can then apply several finish coats to build up the final finished surface using the various means only available in a manufacturing plant. The final surfacing can adapt the panel to its intended use and it may be made resistant to the hazards that can be expected according with its intended use, i.e. the home or a commercial building. Such panel treatment is very diflicult if not impossible to achieve by even a skilled workman on the job after the panel has been put in place, due to the dir'liculty of controlling and maintaining opti-' mum temperatures and dust free atmosphere.

On the job, the prefinished panel is through nailed either to an existing wall or to furring strips, studding or ceiling joints. These normally occur on 16-inch centers and the four foot width usually will be nailed on side margins and on two rows intermediate thereof. Commonly sma l finishing nails or brads are used in a generous number to hold the sheet securely against buckling from changes in humidity. These nails are set below the surface to a depth of one-thirty-second of an inch or greater with a nail set.

Filling the nail holes with a putty knife is most unsatisfactory in installing prefinished panel. There is danger of scratching the surface, and, at best, the putty knife is a crude instrument for the exacting operation of evenly filling the nail holes. Usually considerable pressure is put on the putty knife and a flat side is dragged past the hole to achieve a relatively flush surface and this means increased danger of marring the-finish.

In the present method, the operations are shown in FEGURES 1, 2 and 3.. The nail i2 is set below surface 14 of panel P. The requirement for filling material is that it is non-shrinking in character, it will bond well with the panel material so as to remain fixed in place, and it is colored to match and has the same general sheen as the prefinished panel surface.

The material is formed into a stick S which is presented to the surface 14 so that a relatively sharp edge or corner of the stick, as it rests upon the surface. Such edge can be continuously presented byslightly revolving the stick between the thumb and finger. The stick is passed over the hole in a back and forward operation and in each passage the edge of the hole that is last passed will act as a stripping edge and will shave off a small amount of filler from the stick. This operation is repeated a number of times and preferably from different directions as to insure complete filling of the hole. In subsequent passages of the stick, material on top will press on material below until the hole is completely filled in and a slight excess, as 24, is left on surface 14 contiguous the nail hole.

The next operation is to take a dry cloth as 22, preferably of rough texture such as burlap, and wipe the surface free of excess filler. With a limited amount of practice, a person is able to clean the surface in a single passage of the burlap cloth. If a pronounced grain is present in the panel, then the wiping stroke, or at least the final Wiping stroke, should be in the direction of the grain.

It will be observed from the foregoing that the homeowner can apply this material and yet it is suitable for Work even in a commercial plant. It has been employed successfully on ornamental plastic sheets in factories finishing furniture and employing such material where'it is necessary to fill small cavities such as nail holes.

THE FILLING MATERIAL ing formation or when handled in lower than normal temperatures; (3) being capable of being flaked on the edge of a nail hole as previously described under normal operating conditions; (4) having a high gloss so as to be comparable to the finish of the finished panel and not to be noticeable in casual observation; (5) have wood-adhering and non-shrinking characteristics so as not to change in shape after the cavity has been filled; and (6) being formed of economical materials, consistent with having the foregoing properties, so that the item will be available to the consumer at modestprices.

After very considerable experimentation, the following examples have been developed showing workable formulations. For all of the considerations above in use in prefinished hardwood panels, the formulations are rated in order of preference. It will be understood that some formulations might be more adaptable for one use and some for another, i.e., such additional factors as unusual temperatures, molding facilities, unusually soft materials to be filled etc. In general the formulations below are operative under all conditions usually met:

Example N0. 1

Percent Boiled linseed oil Paraflin, 143-145 AMP 15 Ceramid wax Synthetic Wax No. 2082 35 Carbocera 1191 5 Further identification of these materials will be set forth below.

In making this formulation, the preferred and simplest procedure is as follows: Heat the oil to or approaching 200 F. Add Waxes and heat to 200. Hold at temperature for ninety-six hours. Add alkyd blend color pigments near end of period and then the mixture is ready to be poured into the molds.

, Such color pigments include iron oxide, umbers, siennas, titanium, carbon black, ochres and chromic .oxide and these are added in various proportions to give an assortment of desired wood shades. Colors ground in pure linseed oil are more quickly blended but in using pigments ground in oil it is necessary to make an adjustment in the original amount of linseed oil so as not to change the formulation. Pigments usually vary between 3% and.15% compared by weight to the above. As much as 20% has been added for matching intense colors of ornamental plastic sheets;

To illustrate two color formulations: (1) a pigmentation consisting of the following is suitable for korina, limba, sen and cottonwood:

, Parts Titanium 4 Yellow ocher 3 Burnt umber 1 Chrome yellow light Touch Approx. 12lbs./cwt. base material;

(2) A pigmentation consisting of the following is suitable for Douglas fir, birch, and oak:

Parts Titanium 3 Yellow ocher 2 Burnt sienna 1 Approx. 9 lbs./cwt. base material.

Example N0. 2

Percent Boiled linseed oil 24 Paraffin, -127 AMP 11.5 Emulsowax 1530 58 Carnauba, No. 3 North Country 6.5

The same procedure is used as above except the blend is held at 200 F. for 216 hours. This time is also used in the following formulations. The difference in times of formulations between Example No. 1 and Examples 2 and 5 is probably accounted for by pre-polymerization of There are other natural micro-crystalline, non-crystal line synthetic and crystalline type waxes useable in the formulations. One general classification of these waxes used in the above formulations is in terms of melting point. Number 3 North Country Carnauba has a melting point between 182 and 187 degrees Fahrenheit. A different grade could be used but No. 3 is refined sufliciently. Emulsowax, Ceramid, Carbocera and Synthetic Wax No. 2082 may be termed, in various degrees, carnauba replacements. Carnauba is a high priced material and it is desirable to limit its use.v Another classification for these is that they are all relatively high melting point waxes.

Emulsowax 1530 is one of the Emulsowaxes manufactured by General Wax Refining Company of New York and is the best grade for the present purpose. It has a melting point between about 180 F. and 185 F. and has a hardness needle penetration D-5-25 ASTM 0- /2. If too much of this material is used in the above types of formulations, reaction with parafiin appears to result in some sediment in the mixture. Ceramid is a synthetic crystalline type wax having an approximately 162 F. to 178 F. melting point. It is a product of Glyco Products Company, Inc. Carbocera 1191 is a product of the General Wax Refining Company of New York, has a melting point of 180 -1 82 F., and a hardness penetration of approximately 1. Synthetic Wax No. 2082 was specially manufactured by the General Wax Refining Company for applicant and the best identification available is that it is similar to Emulsowax 1530 only polymerized with oil. Its melting point is about 165 F. to F.

Flexowax C may be termed a lower melting point Wax and melts between 156 F. and 163 F. his a noncrystalline hydrocarbon wax and is a product of Glyco Products Company, Inc, Brooklyn, New York. 7 Other examples of lower melting point waxes comparable to Plexowax C that may be used in the above types of formulation include Magnawax and Durawax. Magnawax is a micro-crystalline wax of the Socony Vacuum Company, having a melting point of 160 F. and a needle penetration, ASTM 77 degrees, 25. Durawax (also reterred to as Multiwax 180) is a micro-crystalline wax sold by the Petroleum Specialties, Inc., of New York City and has an ASTM melting point about 163 and a needle penetration of about 25-35. The Flexowax is preferred because of some problem of compatibility of certain pigments with micro-crystalline waxes.

Carnauba, having the highest melting point, has the capacity of raising substantially the melting point of the mixture when added in samll' quantities. To a lesser degree, the other high melting point waxes listed participate in this quality. On the other hand the dilierences obtained by using 125-127 and 143-145 AMP paraflin are slight. It will be understood that ceresin could be substituted for paraffin, but, parafiin being more economical, this is not a practical commercial device. When, as above, the mixtures are heated for nine orten days, the oil plasticizes the waxes and assists in avoiding brittleness in the stick.

Various types of molding equipment could be used and are known in the trade so only a summary explanation will be provided here, as the molding facility is not a part of this invention:

Melt the ingredients in a stainless steel kettle and after cooking for the above indicated time, pump to a metering valve. Pour from the metering valve into molds. The line from the kettle to the mold is preferably kept from 150 F. to 160 F. The molds should be encased in a drum with cold water circulation. Brass molds are used, each with its own ejector rod, and the sticks remain in the molds from /2 to 1% minutes until ejected. A label may be inserted in the mold just ahead of the needle metering valve. The label is fed from a shoe, through a chute into the mold and then pushed in place by a crimp rod. Thereby the label is molded in place.

With this type of equipment, the polymerization with oil or" the mixture and the relative quantities of high and low melting point material are of importance in avoiding undue resistance to ejection, in avoiding brittleness and yet forming body and sufficient hardness for ejection from the mold. Other considerations include: avoiding brittleness in cold, and plasticity in heat, for handling and storage.

The putty sticks as produced can be described physically in terms of two tests. One is the degree of hardness and the other is the melting point; and the preceding formulations tested as follows:

seconds), cm.

Formulations 1 to 3 are preferred and the needle penetration ranges from 0.04 to 0.05 cm. and the melting points are between 162 F. and 172 F. The overall range of the examples are from 0.02 cm. to 0.05 cm. needle penetration and the melting points are between 158 F. and 172 F. These ranges are variously defined in the claims but are stated as approximations because, as will be understood, the dividing line between operability and inoperability is not sharp. For purposes of comparison, a lipstick was tested and was found to have a needle penetration (50 grams, 72 degrees F., 20 sec- 6 onds) of 0.89 cm. and a melting point of 157 Therefore, the hardness and melting point appear inter-related.

Taking the first three examples as the preferred formulations, the paraflin ranged between 11.5 and 30%, the linseed oil between 15% and 24%, the low melting point waxes, e.g., Flexowax, a maximum of 20%, the high melting point waxes between 35% and 65%, and the total waxes 55%-65%. A more general and operative range is seen in the complete group of examples shown above in which the paraiiin ranges from 11.5 %-40%, the linseed oil between 10% and 25%, the low melting point waxes having a maximum of 20%, the high melting point waxes between 30% and 65% and the waxes in total ranging between 50% and 65%.

Extenders may be added on occasion and two examples are Belgian Whiting and aluminum stearate in use up to as much as 20%. An example of the former is the following: Emulsowax-153025%, Carnauba No. 3 North Country Wax6.5%, -127 AMP paraffin11.5%, polymerized boiled linseed oil24%, Flexowax Cl5%, and Belgian whitingl8%. An example of the latter ,is the following: Boiled linseed oil20-%, 143-145 AMP paraflin-20%, Flexowax C20%, Ceramid30%, Carbocera 1 191-5 aluminum stearate-5%.

Having thus described my invention, I do not wish to be limited tothe exact details of disclosure but instead wish to cover those modifications that will occur to those skilled in the art, as defined in the following claims.

I claim:

l. A stick for filling small cavities in prefinished materials, comprising: an elongated, glossy stick rigid and flaki'ole on the edges of such cavities at normal atmospheric temperatures, said stick having a base material of between about 11.5% and 30% parafiin, between about 15% and 24% boiled linseed oil, between about 55% and 65 waxes having melting points over about 156 F. of which not more than 20% of the total base materials are waxes having melting points below about 162 F., said stick having a needle penetration, 50 grams, 72 F., 20 seconds, of about 0.04 to 0.05 cm. and having a melting point of between about 162 F. and 172 F., and there being pigments added to said base materials whereby the stick matches the color of prefinished material.

2. A stick for filling small cavities in preiinished materials, comprising: an elongated, glossy stick rigid and flabible on the edges of such cavities at normal atmospheric temperatures, said stick having a base material of between about 11.5% and 40% paratfin, between about 10% and 25% boiled linseed oil, between about 50% and 65 waxes having melting points over about 156 F. of which not more than about 20% of the total base material are waxes having metling points below about 162 F., said stick having a needle penetration, 50 grams, 72 F. 20 seconds, of about 0.02 to 0.05 cm. and having a melting point of between about 158 and 172 F. and there being pigments added to said base material whereby the stick matches the color of prefinished maten'al.

3. A stick for filling small cavities in prefinished materials, comprising: a preformed, elongated, glossy stick maintaining its form and flakible on the edges of such cavities at normal atmospheric temperatures, said stick having a base material of boiled linseed oil, paraflin, and Waxes, said stick having a needle penetration, 50 grams, 72 F. 20 seconds, of about 0.04 to 0.05 cm. and having a melting point of between about 162 F. and 172 F., and there being pigments added to said base material whereby the stick matches the color of prefinished material.

4. A stick for filling small cavities such as nail holes in prefinished materials, comprising: a preformed elongated stick maintaining its form and fiakible on the edge of such cavities at normal atmospheric temperatures, said stick having a base material of parafiin, boiled linseed oil, and waxes, said stick having a needle penetration, 50 grams, 72 F. 20 seconds, of between about 0.02 and 0.05 cm. and having a melting point of between about 158 F. and 172 F. and there being pigments added to said base material whereby the stick matches the color of prefinished material.

5. A stick for filling small cavities in prefinished materials, comprising: an elongated, glossy stick rigid and flakible on the edges of such cavities at normal atmos-- base material are waxes having melting points below about 162 F., and there being pigments added to said base material whereby the stick matches the color of prefinished material.

6. A stick for filling small cavities in prefinished materials, comprising: an elongated glossy stick rigid and fiakible on the edges of. such cavities at normal atmospheric temperatures, saidstick having a base material of between about 11.5% and 40% p'arafiin, between about 10% and 25% boiled inlseed oil,'between about 50% and 65% waxes having melting points overabout 156 F. of which not more than, about 20% of the total base material are waxes having melting points below about 162 F., and there being pigments added to said base material whereby the stick matches the color of prefinished material.

7. The subject matter of claim 1, in which the linseed oil is heated to 200 F.; the waxes are then added and the temperature is held for four to nine days.

8. The subject matter of claim 2, in which the blend of materials is heated to 200 F. and held atthis temperature for four to nine days.

9. The subject matter of claim 5, in which the blend of materials is heated to approximately 200 F. and held at this temperature for four to nine days.

References Cited by the Examiner UNITED STATES PATENTS 186,163 1/77 Radde -10619 418,947 1/90 Hart 10619 995,780 6/11 Fuerth 106-245 2,059,409 11/36 Stevens 106-245 20 2,439,207 4/ 48 Feagin 106-245 OTHER REFERENCES Daniels: Patching Damaged Finish, Industrial Finishing, pages 16-21, June 1934.

MORRIS LIEBMAN', Primary Examiner.

JAMES S. BAILEY, JOSEPH REBOLD, JOHN R.

SPECK, Examiners. 

1. A STICK FOR FILLING SMALL CAVITIES IN PREFINISHED MATERIALS, COMPRISING: AN ELONGATED, GLOSSY STICK RIGID AND FLAKIBLE ON THE EDGES OF SUCH CAVITIES AT NORMAL ATMOSPHERIC TEMPERATURES, SAID STICK HAVING A BASE MATERIAL OF BETWEEN ABOUT 11.5% AND 30% PARAFFIN, BETWEEN ABOUT 15% AND 24% BOILED LINSEED OIL, BETWEEN ABOUT 55% AND 65% WAXES HAVING MELTING POINTS OVER ABOUT 156*F. OF WHICH NOT MORE THAN 20% OF THE TOTAL BASE MATERIALS ARE WAXES HAVING MELTING POINTS BELOW ABOUT 162*F., SAID STICK HAVING A NEEDLE PENETRATION, 50 GRAMS, 72*F., 20 SECONDS, OF ABOUT 0.04 TO 0.05 CM. AND HAVING A MELTING POINT OF BETWEEN ABOUT 162*F. AND 172*F., AND THERE BEING PIGMENTS ADDED TO SAID BASE MATERIALS WHEREBY THE STICK MATCHES THE COLOR OF PREFINISHED MATERIAL. 